Combination router-end mill cutter tool, edger with combination tool, and method of edging eyeglass lenses

ABSTRACT

The present invention relates to a tool for shaping and polishing an edge of an eyeglass lens. The tool includes a longitudinally extending body rotatable on the axis thereof, with a proximal portion and a distal portion. A first cutter extends axially and radially from the distal portion, and includes a first blade for shaping an edge of a lens. The distal portion has a first diameter defined by the first blade. A polishing hub is secured to and extends coaxially from the distal portion and is rotatable therewith. A second cutter is secured to and extends coaxially from the polishing hub and is rotatable therewith. The second cutter has a second blade for shaping the edge of the lens. The second blade defines a second diameter less than the first diameter. The present invention also relates to an edger having the disclosed tool, and a method of edging.

FIELD OF THE INVENTION

The present invention is directed to a tool for shaping and polishing anedge of an eyeglass lens. The tool includes a longitudinally extendingbody rotatable on the axis thereof, with a proximal portion and a distalportion. A first cutter extends axially and radially from the distalportion. The first cutter has a first blade for shaping an edge of alens. The distal portion has a first diameter defined by the firstblade. A polishing hub is secured to and extends coaxially from thedistal portion and is rotatable therewith. A second cutter is secured toand extends coaxially from the polishing hub and is rotatable therewith.The second cutter has a second blade for shaping the edge of the lens.The second blade defining a second diameter less than the firstdiameter. The present invention is also directed to an edger having thedisclosed tool, and a method of edging a lens.

BACKGROUND OF THE INVENTION

Prescription eyeglass lenses are curved in such a way that light iscorrectly focused onto the retina of a patient's eye, improving vision.Such lenses are formed from glass or plastic lens “blanks” havingcertain desired properties to provide the correct prescription for thepatient. The blanks are usually circular and of substantially largerdimension, for example 70 mm in diameter and 10 mm, compared to therelatively smaller finished lenses assembled into eyeglass frames.Therefore, a lens blank must be edged to fit an eyeglass frame selectedby the patient.

Ophthalmic laboratory technicians cut, grind, edge, and polish blanksaccording to prescriptions provided by dispensing opticians,optometrists, or ophthalmologists. In addition, the large diameter blankis sized and shaped to fit into the frame selected by the patient. Thelens blank may be shaped using an edger, such as the lens edgerdisclosed in U.S. Pat. No. 6,203,409 to Kennedy et al., the disclosureof which is incorporated herein by reference. The blank is edged so thatthe periphery of the finished lenses fit into the openings on theframes.

Edging of a lens blank typically requires the application of a block toa surface thereof. The block is releasably secured to a clamp assembly,so that rotation of the clamp assembly causes corresponding rotation ofthe lens blank. As the blank is rotated, the periphery of the blank maybe cut to a desired size using a router tool. The lens periphery mayalso be polished using a polishing tool. A bevel is often formed aboutthe lens, particularly adjacent the wearer.

The finished lens may then be assembled with the selected eyeglassframes. The frames include two spaced openings in which the finishedlenses are mounted. The frame openings frequently have a bevel or atongue, which interlocks with a complementarily shaped bevel or groove,respectively, formed about the peripheral edge of the lens. Theinterlock between the complementary bevel and groove helps to secure thelens within the opening. The router and polishing tools on the edgerform the bevel or groove about the lens.

The configuration of the bevel or groove that is edged into theperipheral edge of the lens may vary depending on the configuration ofthe bevel or tongue in the frame openings. Therefore, various router andpolishing tools are provided for forming different bevel or grooveconfigurations. In addition, some frame designs are secured toprotrusions extending from the peripheral edge of the lens. Suchprotrusions are often difficult to form using router blades having arelatively large diameter. Instead, the protrusions may be formed usingan end mill cutter.

The router tools, polishing tools and end mill cutters areinterchangeably secured on the edger via a shaft and chuck assembly.Thus, the technician must change the tool each time a differentconfiguration of the lens edge is needed.

SUMMARY OF THE INVENTION

The present invention relates to a tool for shaping and polishing aperipheral edge of an eyeglass lens. The tool includes a longitudinallyextending body rotatable on the axis thereof. The body has a proximalportion securable to a shaft and a distal portion. A first cutterextends axially and radially from the distal portion, and includes afirst blade for shaping an edge of a lens. The distal portion has afirst diameter defined by the first blade. A polishing hub is secured toand extends coaxially from the distal portion and is rotatabletherewith. The polishing hub has a coating for polishing the edge of thelens. A second cutter is secured to and extends coaxially from thepolishing hub and is rotatable therewith. The second cutter has a secondblade for shaping the edge of the lens. The second blade defining asecond diameter less than the first diameter.

The present invention is also directed to an edger for shaping aperipheral edge of an eyeglass lens. The edger includes a first tablemoveable in a first direction, and a first drive motor for controllablymoving the first table in the first direction. A lens clamping androtating assembly is secured to the first table and is moveabletherewith. The rotating assembly controllably rotates a lens about afirst axis extending generally transverse to the first direction. Asecond table is moveable in a second direction perpendicular to thefirst direction and parallel to the first axis. A second drive motorcontrollably moves the second table in the second direction. A routertool is mounted to the second table and is moveable therewith. Therouter tool is rotatable on a second axis parallel to the first axis.

The tool comprises a longitudinally extending body rotatable on the axisthereof. The body has a proximal portion and a distal portion. A firstcutter extends axially and radially from the distal portion, and has afirst blade for shaping an edge of a lens. The distal portion has afirst diameter defined by the first blade. A polishing hub is secured toand extends coaxially from the distal portion and is rotatabletherewith. The polishing hub has a coating for polishing the edge of thelens. A second cutter is secured to and extends coaxially from thepolishing hub and is rotatable therewith. The second cutter has a secondblade for shaping the edge of the lens. The second blade defines asecond diameter less than the first diameter. A high-speed motor rotatesthe tool at a speed of up to 20,000 RPM.

An edger for shaping an edge of an eyeglass lens according to anotherembodiment is also disclosed. The edger according to the secondembodiment includes a base plate, first and second tables, a lensclamping and rotating assembly, and a router tool. The first table issecured to the base plate and moveable in a first direction. A firstdrive motor controllably moves the first table in the first direction.The second table is secured to the first table and moves in a seconddirection perpendicular to the first direction. A second drive motorcontrollably moves the second table in the second direction. The lensclamping and rotating assembly is secured to the second table andmoveable therewith. The rotating assembly controllably rotates a lensabout a first axis extending generally parallel to the first directionand perpendicular to the second direction. The router tool is mounted tothe base plate and rotatable on a second axis parallel to the firstaxis. The tool comprises a longitudinally extending body rotatable onthe axis thereof. The body has a proximal portion and a distal portion.A first cutter extends axially and radially from the distal portion andhas a first blade for shaping an edge of a lens. The distal portion hasa first diameter defined by the first blade. A polishing hub is securedto and extends coaxially from the distal portion and is rotatabletherewith. The polishing hub has a coating for polishing the edge of thelens. A second cutter is secured to and extends coaxially from thepolishing hub and is rotatable therewith. The second cutter has a secondblade for shaping the edge of the lens. The second cutter has a seconddiameter less than the first diameter. A high-speed motor rotates thetool at a speed of up to about 20,000 RPM.

A method for edging a peripheral edge of an eyeglass lens is disclosed.A lens blank having an edge is provided. A router tool is provided. Therouter tool has first and second cutters. The first cutter has a firstblade for shaping an edge of a lens, and the first cutter defines afirst diameter. A second cutter has a second blade for shaping the edgeof the lens, and the second blade defines a second diameter less thanthe first diameter. The blank is rotated about its geometric axisthereof. A technician selects one of the first and second cutters forshaping the edge of the blank. The edge of the blank is then engagedwith the selected cutter while the router tool is rotating up to 20,000RPM, thereby shaping the edge to one of the first and secondconfigurations corresponding to the selected blade.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of the housing of an edger according to anembodiment of the present invention.

FIG. 2 is a plan view, partially in schematic, of the edger;

FIG. 3 is a fragmentary elevational view taken along line 3-3 of FIG. 2and viewed in the direction of the arrows;

FIG. 3A is a plan view, partially in schematic, of an edger according toa second embodiment;

FIG. 4 is an elevational view of a router tool according to anembodiment of the present invention;

FIG. 5 is an assembly view of the router tool of FIG. 4;

FIG. 6 is a perspective assembly view of a router tool according toanother embodiment, with portions shown in phantom;

FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 5 andviewed in the direction of the arrows;

FIG. 8 is a perspective view of a blade according to one embodiment;

FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 5 andviewed in the direction of the arrows;

FIG. 10 is a perspective view of a lens with protrusions formed in theperipheral edge; and

FIG. 11 is an elevational view of a lens showing the diameters definedby first and second blades.

DETAILED DESCRIPTION OF THE INVENTION

As best shown in FIG. 1, an edger H according to a first embodiment ofthe present invention includes a housing, which encloses the componentswhile permitting operator access to the controls C. The housing includesa lower housing portion 10 to which an upper housing portion 12 ishingedly connected. Upper portion 12 has a window 14 which may be openedby means of hinges or slides 16 to permit operator access to theinterior of the housing. A switch 18 may be secured to window 14 andpivotal therewith, for preventing operation of edger H while window 14is in the raised or open position. Control panel C is mounted to upperportion 12 and provides access by the technician to various controls,collectively 19, of edger H.

As best shown in FIG. 2, edger H includes a base plate 20 within thehousing, to which tables 22 and 24 are mounted for movementperpendicular to each other. Rails 26 and 28 are secured to base 20 andextend in parallel in a first direction relative to base 20. First table22 is slidably mounted to rails 26 and 28 for movement therealong in thefirst direction. Servomotor drive 30 is mounted to base 20 adjacent rail26, and is operably connected to rotary screw 32 for causing controlledrotation thereof. Bracket 34 is secured to first table 22 along theforward edge thereof. Bracket 34 incorporates a ball nut threadedlyengaged with rotary screw 32, so that rotation of screw 32 causescorresponding displacement of the ball nut and hence of bracket 34 andtable 22.

Servomotor drive 36 is mounted to and carried by table 22, and isoperably connected to transmission 38 through motor coupling 40. Shaft42 extends from transmission 38 in a direction transverse to the firstdirection defined by rails 26 and 28. Shaft 42 is controllably rotatedwith precision because of servomotor drive 36 acting throughtransmission 38. Clamp assembly 44 is secured to the end of shaft 42, isrotatable therewith, and is adapted for engagement with an edging blockremovably secured to a lens blank to be edged.

Pneumatic lens clamp cylinder 46 is secured to first table 22 abovedrive 36, and the extensible piston thereof is operably engaged with arm48 for causing movement thereof. Arm 48 carries second clamp assembly50, which is adapted for engaging a lens blank. Actuation of clampcylinder 46 by the technician through one of the controls 19 causesdisplacement of clamp assembly 50 either toward or away from clampassembly 44, thereby clamping or releasing a blocked lens blank. Asknown in the art, a block is releasably secured to clamp assembly 44, sothat rotation of clamp assembly 44 by shaft 42 causes correspondingrotation of the blocked lens blank about the axis of shaft 42.

High speed motor 52 is mounted to second table 24, and has a rotaryshaft 54. The motor 52 preferably rotates shaft 54 at a speed up to20,000 rpm. A router tool T is mounted to shaft 54, and is rotatabletherewith in order for edging, polishing, and safety beveling the lensblank.

Rails 56 and 58 are secured to base 20 and extend in a second directionperpendicular to the first direction defined by rails 26 and 28. Secondtable 24 is slidably mounted to the rails 56 and 58 for movement in thesecond direction defined thereby. Servomotor drive 60 is secured to base20, and drives rotary screw 62. Bracket 64 is secured to second table 24and has a ball nut threadedly engaged with screw 62, so that rotation ofscrew 62 by motor 60 will cause corresponding displacement of bracket 64and hence of second table 24. Because of the precision control providedby servomotor drive 60, rotary screw 62, and the ball nut of bracket 64,precise positioning of tool T relative to a lens blank clamped betweenand rotated by clamp assemblies 44 and 50 is achieved in order to permitthe edging, polishing, and safety beveling process to proceed.

A water supply 66 may be operably associated with base 20. A supply line68 leads to a spray nozzle 70, which is secured to bracket 64 by tubingor light pipe 72, and maintains orientation of nozzle 70 relative totool T as second table 24 slides on the rails 56 and 58. Those skilledin the art will appreciate that pumps and pressure controls are providedin conjunction with water supply 66 so that there is adequate waterpressure for droplet formation by nozzle 70.

As best shown in FIGS. 2 and 3, a rectangular opening 74 may be formedin base 20. A chip chute 76 is mounted to table 24 through brackets orthe like, and defines a plate partially closing opening 74. Aperture 78is formed in chip chute 76 below tool T. A cowl 80 has a duct-likeportion 82 fitted within aperture 78 of chip chute 76. Cowl 80 has aslot 84 providing an opening adjacent tool T for permitting a lens blankclamped between assemblies 44 and 50 to be brought into engagement withtool T through operation of servomotor drive 30. Vacuum line 86 issecured to duct 82 below chip chute 76 for applying a vacuum to cowl 80.Vacuum line 86 terminates at a vacuum source, and causes air,particulates, and water mist to be drawn through cowl 80 to the vacuumsource. Because of opening 74, vacuum line 86 is permitted to move withtable 24 as the table moves in response to operation of servomotor drive60.

An edger H2 according to a second embodiment is best shown in FIG. 3A.Some components of edger H2 are identical to components of edger H, andare identified with like reference numerals. Edger H2 may include alower housing portion 10 and upper housing portion 12 as describedabove, and as shown in FIG. 1.

As best shown in FIG. 3A, edger H2 includes a base plate 20A within thehousing. Preferably, base 20A includes a wall 21 extending outwardlyfrom and perpendicular to base 20A. High speed motor 52 is mounteddirectly to base 20A, and may be mounted to wall 21 using brackets orthe like. Wall 21 includes an opening through which rotary shaft 54extends (not shown). Motor 52 preferably rotates shaft 54 at a speed ofup to 20,000 rpm. Router tool T is mounted to shaft 54 as describedabove. As in the first embodiment, a water supply may be operablyassociated with base 20A proximate router tool T, including a supplyline and spray nozzle.

A first plate 22A is mounted on base 20A via rails 26A, 28A. Rails 26A,28A are secured to base 20A and extend in parallel in a first directionrelative to base 20A. Plate 22A is slidably mounted to rails 26A, 28Afor movement therealong in a first direction. Servomotor drive 30A ismounted to base 20A, and is operably connected to rotary screw 32A forcausing controlled rotation thereof. Servomotor drive 30A may be mountedto wall 21 adjacent motor 52, in which case wall 21 includes an openingthrough which rotary screw 32A extends. First plate 22A includes abracket (not shown) that engages rotary screw 32A so that rotation ofscrew 32A causes movement of first plate 22A along rails 26A, 28A.

A second plate 24A is secured to first plate 22A via rails 56A, 58A(rail 58A is not shown). Rails 56A, 58A are secured to first plate 22Aand extend parallel to each other in a second direction perpendicular tothe first direction defined by rails 26A, 28A. Second plate 24A isslidably mounted to rails 56A, 58A for movement in the second directiondefined thereby. Preferably, rails 56A, 58A lie on a plane spaced fromthe plane of rails 26A, 28A so that movement of first and second plates22A, 24A in the first and second directions is not hindered by rails26A, 28A and 56A, 58A. Servomotor drive 60A is secured to first plate22A, and drives a rotary screw (not shown). A bracket is secured tosecond plate 24A which engages the rotary screw so that rotation of thescrew by motor 60A causes movement of second plate 24A along rails 56A,58A.

A servomotor drive 36A is mounted to and carried by second plate 24A,and is operably connected to a transmission 38A through a motor coupling40A. A shaft 42A extends from transmission 38A in a direction parallelto the first direction defined by rails 26A, 28A. Shaft 42A iscontrollably rotated with precision by servomotor drive 36A actingthrough transmission 38A. As in the first embodiment, a clamp assembly44A is secured to the end of shaft 42A, and is rotatable therewith.Clamp assembly 44A is adapted for engagement with an edging blockremovably secured to a lens blank to be edged.

An electric lens clamp cylinder 46A is secured to second plate 24Aadjacent drive 36A, and the extensible piston thereof is operablyengaged with arm 48A for causing movement thereof. Arm 48A carriessecond clamp assembly 50A, which is adapted for engaging a lens blank.Actuation of clamp cylinder 46A by the technician through one of thecontrols causes displacement of clamp assembly 50A either toward or awayfrom clamp assembly 44A, thereby clamping or releasing a blocked lensblank.

An opening 74A may be formed in base 20A. A chip chute 76A is mounted tobase 20 with brackets or the like, and defines a plate partiallycovering opening 74A. Chip chute 76A may be similar to chip chute 76 inconfiguration, and a detailed description of same will not be repeated.Similarly, a vacuum line may be provided below chip chute 76A andmounted on base 20A, which causes air, particulates, and water mist tobe drawn through an associated cowl to the vacuum source.

Referring now to FIGS. 4 through 9, tool T includes a longitudinallyextending body rotatable on the axis thereof. As best shown in FIG. 4,the body includes a first portion 100 having a first cutter C1, apolishing hub P secured to and extending coaxially from first portion100, and a second portion 102 secured to and extending coaxially frompolishing hub P. Second portion 102 includes a second cutter C2.

As best shown in FIGS. 4-6, first portion 100 includes first and secondopposing ends 104, 106, with a proximal portion 108 proximate first end104 and a distal portion 110 proximate second end 106. Preferably, bothproximal and distal portions 108, 110 have a generally cylindricalconfiguration. Proximal portion 108 preferably has a diameter greaterthan the diameter of distal portion 110. First portion 100 may bemanufactured from grade 303 stainless steel.

Proximal portion 108 may include a coaxially extending bore 112extending inwardly from first end 104 into proximal portion 108, as bestshown in FIG. 6. Bore 112 is configured to receive shaft 54 therein.Threaded openings 114 extend into proximal portion 108 intermediatefirst end 104 and an interface 116 between proximal portion 108 anddistal portion 110. Interface 116 is therefore intermediate and integralwith proximal portion 108 and distal portion 110. Preferably, interfaceextends at an angle between proximal and distal portions 108, 110.Threaded openings 114 preferably extend perpendicularly to bore 112.Threaded fasteners 118 may be screwed into threaded openings 114, sothat the leading ends 117 of fasteners 118 extend into bore 112.

Tool T may be releasably secured to shaft 54 on edger H by sliding shaft54 into bore 112. Fasteners 118 are then screwed into openings 114 sothat leading ends 117 of fasteners 118 are tightened against shaft 54,thereby securing tool T to shaft 54. However, it would be apparent toone skilled in the art that tool T may be secured to shaft 54 usingother securing means, such as a clamp or bolts. Alternatively, bore 112may be threaded for engaging a corresponding threaded portion (notshown) of shaft 54.

Proximal portion 108 may also include a second coaxially extending bore120 extending inwardly from first end 104 into proximal portion 108, andspaced from and parallel to bore 112. Second bore 120 may be provided sothat tool T is balanced when tool T is axially rotated. Second bore 120typically has a diameter substantially less than the diameter of bore112, as best shown in FIG. 6. However, it should be understood that theexact dimensions of second bore 120 may vary depending on the overallconfiguration of tool T.

Distal portion 110 of first portion 100 includes a recess R forreceiving first cutter C1, as best shown in FIGS. 6 and 7. Recess Rincludes first and second sidewalls 122, 124 extending inwardly to abase126. Base includes a first portion 128 and a second portion 130.Preferably, first portion 128 lies on a plane that is angularly disposedrelative to the plane of second portion 130, as best shown in FIG. 7.First portion 128 includes two threaded bores 132 extending into distalportion 110, which preferably extend inwardly perpendicular to the planeof first portion 128.

As best shown in FIG. 6, first cutter C1 includes a blade 134, amounting bracket 136, and mounting screws 138. Mounting bracket 136includes a major portion 140 and a leg 142 angularly disposed relativeto major portion 140. Major portion 140 has openings 144 through whichthe threaded portions of mounting screws 138 may be passed. Mountingbracket 136 is received within recess R so that openings 144 are alignedwith threaded bores 132 in first portion 128 of recess R. Mountingbracket 136 may then be secured in recess R using mounting screws 138.

Although first cutter C1 is shown in FIGS. 4-6 as having a mountingbracket 136 with two openings 144 and two corresponding mounting screws138, it would be understood to one skilled in the art that mountingbracket 136 may be configured to have only one opening 144 or three ormore openings 144. The number of mounting screws used may depend on theoverall configuration of blade 134. It should also be understood thatother fasteners may be used for securing blade 134 to distal portion110.

As best shown in FIGS. 7 and 8, blade 134 includes a first side 146having a cutting edge 148, a second side 150, and a sloped portion 152extending downwardly from cutting edge 148 to second side 150. Cuttingedge 148 may have any desired configuration, depending on the desiredshape to be formed in the perimeter of the lens blank during the edgingoperation.

As best shown in FIG. 8, cutting edge 148 may include a first edge 154,a second edge 156 spaced from first edge 154, and a contoured edge 158intermediate and integral with first and second edges 154, 156. Firstand second edges 154, 156 may be either coplanar, or they may lie onplanes that are spaced from each other. Contoured edge 158 may beV-shaped, with first and second walls 160, 162. First wall 160 extendsdownwardly from first edge 154 at a first angle, and second wall 162extends downwardly from second edge 156 at a second angle. First andsecond angles may be the same, or first and second walls 160, 162 mayextend downwardly at different angles.

It should be understood that cutting edge 148 may have anyconfiguration. For example, contoured edge 158 may include a portionhaving an arcuate profile and/or a portion that is substantiallyperpendicular to first or second edges 154, 156. Contoured edge 158 mayalso extend outwardly relative to first and second edges 154, 156. Thus,cutting edge 148 shown in FIG. 8 is for purposes of explanation only,and the invention is not limited to same.

The configuration of cutting edge 148 is a mirror image of the edge thatwill be formed about the perimeter of the lens blank. Thus, an inwardlyextending V-shaped contoured edge 158 will form an outwardly extendingV-shaped bevel about the perimeter of a lens. Similarly, a cutting edge148 having an outwardly extending contoured edge (not shown) will forman inwardly extending groove about the perimeter of the lens blank.

As best shown in FIG. 7, blade 134 is positioned in recess R and againstsecond portion 130 of base 126, so that second side 150 of blade 134abuts second sidewall 124 of recess R. When blade 134 is positioned inrecess R, cutting edge 148 extends axially and radially from distalportion 110. Mounting bracket 136 is positioned in recess R, withopenings 144 aligned with threaded bores 132 in first portion 128 ofbase 126. Leg 142 of mounting bracket 136 abuts first side 146 of blade134. The threaded portions of mounting screws 138 pass through openings144, and may be screwed into threaded bores 132. As mounting screws 138are screwed into threaded bores 132, leg 142 is tensioned against firstside 146 of blade 134 due to the angular configuration of leg 142. Thus,as mounting bracket 136 is secured in recess R, blade 134 is alsosecured therein. Blade 134 may be easily removed and/or replaced bysimply loosening mounting screws 138, thereby releasing the tensionbetween leg 136 and first side 146 of blade 134. Once mounting bracket136 is loosened, blade 134 may be easily slipped out of recess R.

Distal portion 110 of first portion 100 may include a groove 164 formedperipherally about distal portion 110 and aligned axially with contourededge 158 when blade 134 is secured in recess R, as best shown in FIGS.4-6. If blade 134 is being installed and/or replaced, the techniciansimply lines up contoured edge 158 with groove 164. Groove 164 permitscontoured edge 158 and therefore blade 134 to be precisely oriented inrecess R.

As best shown in FIGS. 5 and 6, distal portion 110 preferably includes acoaxially extending projection 166 extending outwardly from second end106 of first portion 100. Projection 166 may include an internallythreaded coaxial bore 168 extending inwardly from the distal end ofprojection 166, as best shown in FIG. 7.

As best shown in FIGS. 4 and 5, polishing hub P preferably has agenerally cylindrical configuration, with opposing first and second ends170, 172. Polishing hub P preferably has a diameter corresponding to thediameter of distal portion 110 as defined by cutting edge 148 of blade134, as best shown in FIG. 4.

As best shown in FIGS. 9 and 10, polishing hub P may include a coaxiallyextending bore 174 extending therethrough, from first end 170 to secondend 172. In one embodiment, bore 174 includes a first portion 176 havinga first diameter and extending inwardly from second end 172 of polishinghub P, and a second portion 178 having a second diameter greater thanthe first diameter extending inwardly from first end 170 of polishinghub, as best shown in FIG. 9. A shoulder 180 is intermediate andconnects first and second portions 176, 178 of bore 174. First portion176 of bore 174 is configured for receiving projection 166 therein.

Preferably, polishing hub P has throughout the entirety of its outerlens-contacting surface 182 a 600 girt diamond material bonded thereto,such as provided by Inland Diamond Company. The diamond bond preferablyhas a thickness of about 0.125 inch in order to accommodate wear, andprovides an abrasive coating with numerous fine cutting edges. As knownin the art, the edging process sometimes causes the resulting blank edgeto have a smoky or distressed finish. The smoky finish is believed toarise from microscopic score lines formed in the edge of blank whilebeing edged. The diamond grit material on polishing hub P removes thescore lines creating the smoky finish, as well as other imperfections,so that the resulting edge of the blank has a polished translucentappearance. The 600 girt diamond material is preferably bonded in abronze-iron matrix. It should be understood that polishing hub P mayinclude other abrasive coatings, such as finer or coarser diamond grit.Further, the diamond grit or other abrasive coating may be plated ontopolishing hub P. The coating used will depend on the desired finish onthe lens blank, as well as the material used to form the lens blank.

Polishing hub P may include a V-notch 184 formed about outer surface 182and parallel to groove 164 on distal portion 110, as best shown in FIG.4. V-notch 184 extends continuously about outer surface 182. V-notch 184has a similar configuration to contoured edge 158 of blade 134, so thatthe resulting bevel in the lens blank formed by cutting edge 148 may bealigned with V-notch 184. In this way, the perimeter of the lens blank,including the formed bevel, may be polished without removing the bevel.V-notch 184 may have any desired configuration, preferably matching theconfiguration of contoured edge 158.

As best shown in FIGS. 4, 5 and 9, polishing hub P may also include achamfer 186 extending angularly and outwardly from first end 170 toouter surface 182 relative to the axis of rotation. Preferably, chamfer186 extends at an angle of 45°. Chamfer 186 provides an angled surfaceupon which to remove the sharp corner formed at the intersection betweenthe major surfaces and the perimeter edge of the resulting lens. Thecorner of the lens is adjacent the wearer, and thus removing that cornerpromotes safety by reducing the possibility that the wearer may becomecut if contacted by that corner.

As best shown in FIGS. 4-6, second portion 102 includes a central body188 having a generally cylindrical configuration with first and secondends 190, 192. A second cutter C2 extends outwardly from first end 190.Second cutter C2 may be an end mill cutter. Second cutter C2 has adiameter less than the diameter distal portion 110 as defined by cuttingedge 148 of blade 134 when secured thereto, as best shown in FIGS. 4 and5.

As best shown in FIGS. 5 and 6, second portion 102 also includes aprojection 194 extending outwardly from second end 192 of central body188, and coaxial with second cutter C2. Projection 194 preferably has agenerally cylindrical configuration, with a diameter less then thediameter of central body 188. Projection 194 also preferably includes athreaded end 196, as best shown in FIG. 5.

As best shown in FIGS. 5 and 6, tool T is assembled by insertingprojection 166 of first portion 100 into first portion 176 of polishinghub P so that second end 172 abuts second end 106 of distal portion 110.Then, projection 194 of second portion 102 is inserted into secondportion 178 of polishing hub P until threaded end 196 of projection 194engages threaded coaxial bore 168 in projection 166. Threaded end 196 isscrewed into bore 168 until a tight connection is achieved. Whentightened therein, projection 194 extends into first portion 176 ofpolishing hub, and a portion of central portion 188 adjacent second end192 fits into second portion 178 of bore 174 of polishing hub P.Preferably, second end 192 abuts shoulder 180 of polishing hub P. Itshould be understood, however, that polishing hub P may be independentlysecured to first portion 100, and second portion may be independentlysecured to polishing hub P.

As best shown in FIG. 10, a lens blank B may be shaped to have knobs 200extending outwardly from the perimeter 202 of blank B. The resultinglens have knobs that may then be secured to “rimless” frames which clamponto the knobs 200, as opposed to conventional frames which surround theperimeter 202 of the lens. Such knobs 200 may be difficult to form usinga cutter having a relatively large diameter, given the angle between theperimeter 202 and the portion of the knob extending outwardly therefromis restricted by the diameter of the cutter being used. Second cutter C2has a relatively small diameter compared to first cutter C1, and allowsfor precision edging even between surfaces disposed from each other byrelatively sharp angles.

For example, as best shown in FIG. 11, it would be difficult to form aknob 200 that extends outwardly from perimeter 202 at a relatively sharpangle using a cutter C1′ having a relatively large diameter. Cutter C1′is unable to remove all of the material near the base 204 of knob 200due to the relatively large diameter of cutter C1′, as shown in FIG. 11.A cutter C2′ having a relatively small diameter is better able to formthe steep sides of knob 200.

Therefore, tool T includes first portion having a first cutter C1 forshaping an edge of a lens. First cutter C1 defines a first diameter.Second portion includes second cutter C2 also for shaping the edge ofthe lens, but having a second diameter less than the first diameter.When secured to shaft 54 on edger H, a technician may select one offirst and second cutters C1, C2 for shaping the edge of the blank to thedesired configuration. The perimeter 202 of the blank B engages theselected cutter C1 or C2 as tool T is rotated by edger H, preferablyrotating at up to 20,000 RPM. Tool T may be used to form variousconfigurations about the perimeter 202 of blank B, as well as polishblank B to shape and finish the resulting lens.

It will be apparent to one of ordinary skill in the art that variousmodifications and variations can be made in construction orconfiguration of the present invention without departing from the spiritof the invention. Therefore, it is intended that the present inventioninclude all such modifications or variations, provided they come withinthe scope of the following claims and their equivalents.

1. A tool for shaping and polishing a peripheral edge of an eyeglasslens, comprising: a longitudinally extending body rotatable on the axisthereof, said body having a proximal portion securable to a shaft and adistal portion; a first cutter extending axially and radially from saiddistal portion, said first cutter having a first blade for shaping anedge of a lens, said distal portion having a first diameter defined bysaid first blade; a polishing hub secured to and extending coaxiallyfrom said distal portion and rotatable therewith, said polishing hubhaving a coating for polishing the edge of the lens; and a second cuttersecured to and extending coaxially from said polishing hub and rotatabletherewith, said second cutter having a second blade for shaping the edgeof the lens, said second blade defining a second diameter less than saidfirst diameter.
 2. The tool of claim 1, wherein said second cutter is anend mill cutter.
 3. The tool of claim 1, wherein said polishing hub isgenerally cylindrical with first and second ends.
 4. The tool of claim3, wherein said polishing hub has a diameter substantially equal to saidfirst diameter.
 5. The tool of claim 3, wherein said polishing hubincludes a coaxially extending bore extending from said first end tosaid second end.
 6. The tool of claim 5, wherein said body furthercomprises a projection extending outwardly from and coaxial with saiddistal portion, said projection receivable in said polishing hub bore.7. The tool of claim 6, wherein said projection including a coaxiallyextending, threaded bore extending from an outer end into saidprojection.
 8. The tool of claim 7, wherein said second cutter includesa threaded projection opposite said second blade, said threadedprojection receivable in said polishing hub bore through said secondend, said threaded projection releasable securable in said threaded boreso that said polishing hub is securable therebetween.
 9. The tool ofclaim 1, wherein said polishing hub includes a first portion proximatesaid first cutter and a second portion proximate said second cutter. 10.The tool of claim 9, wherein said second portion has a chamfer.
 11. Thetool of claim 1, wherein said coating is a diamond grit coating.
 12. Thetool of claim 1, wherein said first blade includes a first edge, asecond edge spaced from said first edge, and a contoured edgeintermediate and integral with said first and second edges, saidcontoured edge for forming a bevel about the edge of the lens.
 13. Thetool of claim 12, wherein said contoured edge is V-shaped.
 14. The toolof claim 12, further comprising a groove formed peripherally about saiddistal portion and aligned axially with said contoured edge.
 15. Thetool of claim 14, wherein said groove is V-shaped.
 16. The tool of claim1, wherein said distal portion is generally cylindrical.
 17. The tool ofclaim 1, wherein said proximal portion is generally cylindrical and hasa third diameter greater than said first diameter.
 18. The tool of claim1, wherein said proximal portion includes a coaxially extending boreextending from a first end into said proximal portion for receiving theshaft therein.
 19. The tool of claim 1, wherein said distal portionincludes a recess having a base and first and second sidewalls.
 20. Thetool of claim 19, wherein said first cutter is releasably securable insaid recess.
 21. The tool of claim 20, wherein said base includes afirst portion lying on a first plane, and a second portion angularlydisposed relative to the plane of said first portion.
 22. The tool ofclaim 21, wherein said first cutter is removeably securable in saidsecond portion using a mounting bracket and fastener.
 23. The tool ofclaim 22, wherein said first portion includes a threaded bore forreceiving said fastener and securing said mounting bracket thereto. 24.The tool of claim 22, wherein said mounting bracket includes a majorportion and a leg angularly disposed relative to said major portion. 25.The tool of claim 24, wherein a first side of said first cutter ispositioned against said first sidewall of said recess, and said leg isreleaseably tensioned against a second side of said first cutteropposite said first side for securing said cutter therein.
 26. An edgerfor shaping a peripheral edge an eyeglass lens, comprising: a firsttable moveable in a first direction, and a first drive motor forcontrollably moving said first table in said first direction; a lensclamping and rotating assembly secured to said first table and moveabletherewith, said rotating assembly for controllably rotating a lens abouta first axis extending generally transverse to said first direction; asecond table moveable in a second direction perpendicular to said firstdirection and parallel to said first axis, and a second drive motor forcontrollably moving said second table in said second direction; a routertool mounted to said second table and moveable therewith, said routertool rotatable on a second axis parallel to said first axis and saidtool comprising a longitudinally extending body rotatable on the axisthereof, said body having a proximal portion and a distal portion, afirst cutter extending axially and radially from said distal portion,said first cutter having a first blade for shaping an edge of a lens,said distal portion having a first diameter defined by said first blade,a polishing hub secured to and extending coaxially from said distalportion and rotatable therewith, said polishing hub having a coating forpolishing the edge of the lens, and a second cutter secured to andextending coaxially from said polishing hub and rotatable therewith,said second cutter having a second blade for shaping the edge of thelens, said second cutter having a second diameter less than said firstdiameter; and a high-speed motor for rotating said tool at a speed of upto about 20,000 RPM.
 27. The edger of claim 26, further comprising anozzle secured to said second table and moveable therewith, said nozzledisposed adjacent to and aligned with said router tool for selectivelydirecting coolant fluid thereto.
 28. An edger for shaping an edge of aneyeglass lens, comprising: a base plate; a first table secured to saidbase plate and moveable in a first direction, and a first drive motorfor controllably moving said first table in said first direction; asecond tables secured to said first table and moveable in a seconddirection perpendicular to said first direction, and a second drivemotor for controllably moving said second table in said seconddirection; a lens clamping and rotating assembly secured to said secondtable and moveable therewith, said rotating assembly for controllablyrotating a lens about a first axis extending generally parallel to saidfirst direction and perpendicular to said second direction; a routertool mounted said base plate, said router tool rotatable on a secondaxis parallel to said first axis and said tool comprising alongitudinally extending body rotatable on the axis thereof, said bodyhaving a proximal portion and a distal portion, a first cutter extendingaxially and radially from said distal portion, said first cutter havinga first blade for shaping an edge of a lens, said distal portion havinga first diameter defined by said first blade, a polishing hub secured toand extending coaxially from said distal portion and rotatabletherewith, said polishing hub having a coating for polishing the edge ofthe lens, and a second cutter secured to and extending coaxially fromsaid polishing hub and rotatable therewith, said second cutter having asecond blade for shaping the edge of the lens, said second cutter havinga second diameter less than said first diameter; and a high-speed motorfor rotating said tool at a speed of up to about 20,000 RPM.
 29. Amethod for edging a peripheral edge of an eyeglass lens, comprising thesteps of: providing a lens blank having an edge; providing a router toolhaving a first cutter having a first blade for shaping an edge of alens, the first cutter defining a first diameter, and a second cutterhaving a second blade for shaping the edge of the lens, the secondcutter defining a second diameter less than the first diameter; rotatingthe blank about the geometric axis thereof; selecting one of the firstand second cutters for shaping the edge of the blank; and engaging theedge with the selected cutter while the router tool is rotating up to20,000 RPM and thereby shaping the edge to one of the first and secondconfigurations corresponding to the selected blade.